Seamless bra

ABSTRACT

The present invention provides a bra that is preferably formed of seamless construction and that includes structural components that allow for accommodating changes and variations in bust size. In particular, the inventive bra can be used during times of maternity when breast volume is known to increase over a short time. The bra comprises expansible cups with interchangeable, formed support and shape elements that can be placed into pockets formed in the expansible cups. In certain embodiments, the invention also provides a bra for use when breast feeding, the bra comprising a drop-down panel.

FIELD OF THE INVENTION

The present invention is directed to a woman's foundation garment, and more particularly a bra. The inventive bra specifically provides an expansible cup to accommodate changes in bust dimensions, such as during pregnancy.

BACKGROUND OF THE INVENTION

A brassiere, commonly known as a bra, is well recognized as an article of clothing, particularly an undergarment, used to cover, support, and elevate the breasts. The roles of bras can vary from mere style to more practical uses, as noted above.

A bra usually consists of two cups for breasts, a centre panel (known as a gore), a band running around the torso under the bust, and a shoulder strap for each side. Brassieres are typically made of a fabric, such as cotton or polyester, although other materials, such as spandex and lace may be used for various parts of the bra. The cups for the breasts may be reinforced by underwires made of metal sometimes coated in plastic. The bra is usually fastened with a hook fastener on the band, typically at the back. In some bras the fastener is in the front, between the cups. Others are pulled on over the head and have no fasteners at all.

The comfort and function of any given bra is highly dependent on having a correct size and fit. Although all bras are labeled by size, many women find that the only way to obtain a bra that fits properly and achieves the effect they want is by trying a bra on with each bra type, model and brand. There are several methods which may be used to provide an approximate size by taking measurements; however, bra sizing systems differ widely between countries, between manufacturers, and between brands and designs, which can create many problems. This is often because fit requires an accurate measurement of the breast volume, not merely the body circumference, which typically is what is actually measured.

Although bra sizing uses the circumference to estimate the volume, this has been shown to be highly unreliable. For example, a first measurement is typically taken under the breasts as tight as possible, and a second measurement is taken as a loose fit of the chest circumference over the fullest part of the breasts. The cup size can then be calculated with tables or a conversion tool from the difference between these two measurements.

Although breast size is often equated to bra size, it is not an accurate description. While most people recognize that bra sizes are typically described by a numbering and lettering system, few people realize the intricacies in achieving an appropriate bra fit. Bra size is commonly described by two values: 1) the band length, which is based on chest circumference under the bust, excluding the breasts; and 2) the cup size (e.g., a “34C” bra). It is essential that the bra fit correctly in both of the bra size descriptors.

Cup size is only a relation to actual breast volume. Common bra cup sizes are (from smaller to larger) “AA”, “A”, “B”, “C”, “D”, and “DD”, and increasingly larger sizes are also available and denoted alphabetically, including double or triple lettering systems. The general relation between common cup sizes and the actual volume of the cup are: size “A”—8 fl. oz. (236 cm³); size B—13 fl. oz. (384 cm³); size C—21 fl. oz. (621 cm³); and size “D”—27 fl. oz. (798 cm³).

Bras are made in a large variety of shapes and sizes to accommodate all body types. Although breast size is often generally consistent over time for adults, rapid changes in size can take place. For example, pregnancy can particularly cause a rapid increase in breast size, often followed by a rapid decrease in breast size (after birth), especially after ceasing breast feeding. Of course, breast size can also change due to weight fluctuations or other causes apart from pregnancy. Moreover, the size and shape of a woman's breasts can vary during her menstrual cycle.

Times of rapid breast size changes can be quite costly, and purchasing a sufficient number of bras in a new size can cost several hundred dollars. During pregnancy, for example, bra cup size can increase by one, two, or even three sizes. Moreover, body circumference can change significantly, which also rapidly alters the bra size, as described above.

In addition to rapid changes in breast size, other factors can affect achieving and maintaining proper bra sizing. For example, studies have indicated that most women have asymmetrical breasts (10% being severely asymmetrical). See Losken A., et al., (2005) “An Objective Evaluation of Breast Symmetry and Shape Differences Using 3-Dimensional Images”, Annals of Plastic Surgery, 55(6): 571-575.

In light of the above, there remains a need in the art for a bra that can provide proper fitting in relation to both body circumference and actual breast volume. Moreover, there is a need for a bra that can accommodate rapid changes in breast size, as well as breast asymmetries. The present invention fills this void in the art.

SUMMARY OF THE INVENTION

The present invention provides a bra having expansible cups. In particular, the cups are formed to have a base size that is the minimum cup size but to be capable of expanding to accommodate a larger breast volume. The inventive bra can also comprise additional components that are useful to enable a single bra to provide an accurate fit over a range of sizes, including overall bra circumference, cup size, or both overall circumference and cup size.

In one aspect, the present invention is directed to a bra that has expansible cups. In particular embodiments the expansible cups comprise an open access pocket. In other words, the cups may comprise an inner layer and an outer layer that combined so as to form a pocket. Moreover, the pocket is formed so that it is openly accessible from outside the pocket. In particular embodiments, the open access pocket is designed for receiving a formed support and shape element that substantially corresponds to a particular bra cup size. In certain embodiments, the bra specifically includes a formed support and shape element for each extensible cup.

In further embodiments, the bra cups may be designed so that the pocket formed therein is concealed from external view. For example, the bra cups may be designed so that the pocket is accessible on an inward-facing surface of the expansible cup.

The bra of the invention may further comprise backwings extending laterally away from the expansible cups. In specific embodiments, the backwings may further encompass a portion of the bra body directly under the cups. Moreover, the backwings may meet at the midline of the bra. Preferably, the backwings have a double-folded, textured woven construction (e.g., a variegated rib construction).

Positioned at the terminal ends of each backwing may be closure means for attaching the two ends of the backwings and thus secure the bra to the user. For example, the bra may comprise a series of eyelets at an end of one backwing and a series of hooks at an end of the other backwing. In specific embodiments, the bra can also comprise a separable eye and hook extension piece that effectively expands the overall circumference of the bra.

The bra may also comprise still further components. For example, in one embodiment, the bra comprises a hemmed lower edge having a double-folded, textured woven construction. In further embodiments, the bra comprises a center gore formed between the expansible cups. In particular, the center gore may have a reduced stretch ability in relation to the expansible cups. Moreover, the center gore may be constructed to form a vertical gathering of the cups near the center gore.

In particular embodiments, the bra may be particularly designed to provide access to an underlying breast for breast feeding a baby. For example, in one embodiment, the pocket formed in the cup by the inner and outer cup layers is a drop-down pocket. More specifically, at least one cup may be formed of an outer material layer and an inner material layer, each layer comprising a top portion that is independently attached to a connecting piece. The connecting piece can particularly connect the outer material layer and the inner material to an over-shoulder strap. In specific embodiments, the inner material layer can be permanently attached to the connecting piece and the outer material layer can be releasably attached to the connecting piece. Thus, upon release of the connection of the outer layer to the connecting piece, the outer layer can drop down to reveal the underlying inner cup layer and/or the underlying breast. In some embodiments, the inner material layer and the outer material layer can be aligned in a sufficiently offset manner such that release of the connection of the outer material layer allows the outer material layer to drop down and expose the underlying breast of a user. Alternately, if the underlying inner layer covers the breast, it can be easily moved aside to facilitate breast feeding.

The bra of the present invention can be particularly described as having a seamless construction. More specifically, the bra may comprise a bra body that is formed of a seamless construction. In particular embodiments, the bra body may be defined as encompassing the expansible cups, the backwings, an optional hem on the bottom edge of the bra, and an optional center gore. In a specific embodiment, the seamless bra body comprises the cups, backwings, hem, and center gore.

In another aspect, the present invention also comprises a bra kit. In specific embodiments, a bra kit according to the invention provides a bra that is adaptable to a variety of breast sizes. In particular, the bra kit may include a bra that comprises expansible cups, each cup having an open access pocket. The kit may further include a plurality of pairs of support and shape elements designed for insertion into the open access pocket, each pair of support and shape elements being formed to substantially correspond to different particular bra cup sizes. Of course, a variety of types, shapes, sizes, and styles of support and shape elements could be included in the kit covering a range of bra cup sizes. In further embodiments, the bra kit may further comprise a separable eye and hook extension piece that effectively expands the overall circumference of the bra.

In some embodiments, the invention comprises a non-surgical method of correcting a breast size asymmetry (i.e., having one breast that is smaller than the other). In particular, the method may comprise providing a bra according to the invention, providing padding material to appropriately fill the pocket in the bra cup corresponding to the smaller breast, and providing instruction for filling the pocket so that wearing the bra with the padding provides an outward appearance of breast symmetry. The invention can include similar methods for correcting other breast size or shape conditions.

In another aspect, the invention is directed to a method of making a bra with expansible cups. In one embodiment, the method comprises the following steps: A) forming a preliminary bra body having a tubular construction and comprising a material that is elastic in multiple directions; B) shaping the preliminary bra body to have a top edge and a bottom edge and to define two expansible cups having an inner layer and an outer layer; and C) trimming the top edge of the preliminary bra body to form a finished bra body, wherein the inner and outer expansible cup layers are joined by the trimming on the top edges of the cups leaving an opening that forms an open access pocket in the expansible cup.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described the invention in general terms, reference will now be made to the accompanying drawings, wherein:

FIG. 1 is front (exterior) view of a bra according to one embodiment of the invention having expansible cups;

FIG. 2 is a detail view of the body contacting inner surface of an expansible cup of a bra according to one embodiment of the invention illustrating an opening for accessing the cup pocket;

FIG. 3 is an illustration of a formed support and shape element according to one embodiment of the invention for insertion into a bra cup pocket;

FIG. 4 is a partial front view of a bra according to one embodiment of the invention having a drop-down panel (in the raised position);

FIG. 5 is a partial front view of a bra according to one embodiment of the invention having a drop-down panel (in the dropped position); and

FIG. 6 is a schematic drawing of a bra according to one embodiment of the invention illustrating areas of measurement for various portions of the bra, the measurements being provided in Table 1.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now will be described more fully hereinafter. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The terminology used herein is for describing particular embodiments only, and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

A bra according to one embodiment of the invention is illustrated in FIG. 1. The body of the bra is beneficially formed of a seamless construction. Accordingly, the bra body can be described in terms of being a singly constructed piece and not a conglomeration of individual pieces or sections that are seamed or otherwise connected together. This seamless construction is particularly beneficial for increasing bra comfort and support, as well facilitating other inventive aspects of the bra, as described herein. While the bra body may be described herein in term of particular part (such as cups, backwings, a lower hem, and a center gore), the bra body still remains a seamless and uniform piece with the specified parts being shaped and made structurally distinct and identifiable through the manufacturing techniques and methods described herein.

The bra 100 illustrated in the embodiment of FIG. 1 comprises two expansible cups 111 and 118. The expansible cups are a particularly unique aspect of the present invention that enables the inventive bra to literally “grow” with the body of a user. The bra body, including the cups, can be formed from a variety of materials and combinations of materials. Preferably, the bra body is formed using one or more materials formed of yarns and/or fibers having a stretch recovery (i.e., exhibit recoverable stretch). The terms “stretch recovery” and “recoverable stretch” are used interchangeably herein and refer to the ability of a material to contract upon termination of a biasing force following stretching (i.e., increasing in length) of the material by application of the biasing force. Determination of the recoverable stretch of yarns can be made using the test procedure of ASTM D6720, wherein recoverable stretch is typically reported as a percentage of recovery upon loading and unloading of a force. In certain embodiments, fabrics and materials used to prepare a bra body according to the present invention comprise yarns and/or fibers that exhibit at least a minimum percentage of stretch recovery. Preferably, the stretch core yarn exhibits a recoverable stretch of at least about 10%, at least about 15%, at least about 20%, at least about 25%, or at least about 30%. Use of such yarns and/or fibers beneficially provides for materials exhibiting stretch recovery in multiple directions. In other words, the material stretches and recovers when the material is pulled in any two opposing directions across the plane of the material.

Any material or combination of materials providing a stretch ability as described herein could be used according to the invention to form the bra body. For example, the bra body could be formed using naturally elastomeric materials. The term elastomeric material, or elastomer, is often used interchangeably with the term rubber and can encompass natural rubbers as well as synthetic rubbers. Elastomeric materials are amorphous polymers existing above their glass transition temperature so that considerable segmental motion is possible. In other words, an elastomer can be considered to be any amorphous polymer having a glass transition temperature (T_(g)) below ambient temperature. Examples of elastomers include polyisoprene, polybutadiene, polyisobutylene, and polyurethanes. One specific example of a material exhibiting a stretch recovery useful according to the invention is spandex, a block copolymer including polyurethane.

Stretch materials according to the invention can also be combined with more conventional materials. Such conventional materials can be formed using natural and/or synthetic fibers. Non-limiting examples of materials that may be used to prepare a bra according to the invention include cotton, polyesters (e.g., polyethylene terephthalate) polyamides (e.g., nylon), and cellulosic fibers (e.g., rayon). In particular embodiments, the material used to prepare a bra according to the invention preferentially comprises a content of spandex or other fibers providing similar properties. For example, the material may comprise up to about 30% by weight spandex or up to 25% by weight spandex. In other embodiments, the material may comprise about 5% to about 25% by weight spandex. Of course, various blends of fibers are also encompassed by the invention, such as polyester/cotton/spandex or rayon/nylon/spandex. In one embodiment, a bra body according to the invention is comprised of a combination of nylon and spandex (e.g., at nylon:spandex weight ratios of about 95:5, about 92:8, about 90:10, about 88:12, about 85:15, about 80:20, or about 75:25, based on the overall weight of the material).

Typical bras are designed to be a specific size (i.e., specific circumference and specific cup volume). Thus, when the breasts of a user grow, the user is required to purchase a bra of a bigger pre-set size. As pointed out above, however, the expansible nature of the bra cups of the present invention allows the cups to expand and comfortably accommodate increases and decreases in breast volume. Thus, a single bra according to the invention can be worn comfortably throughout a span of time encompassing a change in breast volume that would otherwise typically require changing to a bra of a different pre-set size. In specific embodiments, a single bra according to the invention comprises cups that can accommodate breast volumes that span a range exceeding what would normally be accommodated by a bra having a pre-set size.

In some embodiments, a single bra according to the invention comprises expansible cups that will provide comfort and support in two standard cup sizes. This is meant to indicate that a single bra according to the invention would be capable of accommodating breast volumes that would normally fall into two commonly recognized breast volume sizing schemes. For example, a single bra according to the invention would comfortably support breasts having a normally recognized “B” cup size and a normally recognized “C” cup size. In other embodiments, a single bra according to the invention comprises expansible cups that will provide comfort and support in three standard cup sizes (e.g., a normally recognized “B” cup size, a normally recognized “C” cup size, and a normally recognized “D” cup size).

The invention also recognizes that some bra manufacturers currently provide bras in intermediate sizes that fall between the normally recognized cup sizes. For example, one manufacturer provides range of half-sizes between cup sizes A and D (e.g., sizes A, A½, B, B½, C, C½, and D). In light of such half sizes, a single bra according to the invention can comprise expansible cups that will provide comfort and support in two, three, four, five, or even six different recognized cup sizes.

In certain embodiments, a bra according to the invention can be characterized by the ability of the expansible cups in a single bra to provide comfort and support across a specified range of actual breast volumes. In specific embodiments, the cups of a single bra according to the invention can provide comfort and support for breasts having a volume that varies over a range of 4 fl. oz. (118 cm³), 5 fl. oz. (148 cm³), 6 fl. oz. (177 cm³), 7 fl. oz. (207 cm³), 8 fl. oz. (236 cm³), 9 fl. oz. (266 cm³), 10 fl. oz. (296 cm³), 11 fl. oz. (325 cm³), 12 fl. oz. (355 cm³), 13 fl. oz. (384 cm³), 14 fl. oz. (414 cm³), 15 fl. oz. (444 cm³), 16 fl. oz. (473 cm³), 17 fl. oz. (503 cm³), 18 fl. oz. (532 cm³), 19 fl. oz. (562 cm³), or 20 fl. oz. (591 cm³). In other embodiments, cup volume can vary in a range of from 2 fl. oz. (59 cm³) to 15 fl. oz. (444 cm³), from 3 fl. oz. (89 cm³) to 14 fl. oz. (414 cm³), from 4 fl. oz. (118 cm³) to 13 fl. oz. (384 cm³), from 5 fl. oz. (148 cm³), to 12 fl. oz. (355 cm³), from 5 fl. oz. (148 cm³), to 11 fl. oz. (325 cm³), or from 5 fl. oz. (148 cm³) to 10 fl. oz. (296 cm³).

Bras according to the invention can be provided in a variety of sizes themselves to accommodate varying ranges of cup volumes. For example, a “small” bra according to the invention could accommodate breast volumes from about 2 fl. oz. (59 cm³) to about 21 fl. oz. (621 cm³), a “medium” bra according to the invention could accommodate breast volumes from about 13 fl. oz. (384 cm³) to about 27 fl. oz. (798 cm³), and a “large” bra according to the invention could accommodate breast volumes from about 21 fl. oz. (621 cm³) to about 35 fl. oz. (1035 cm³). Of course, these are just exemplary ranges, and bras of varying cup volumes could be formed with the knowledge of the present invention.

The seamless bra body according to the invention, in light of the manufacturing process described in greater detail below, can have an essentially double layer structure. The unique combination of knitting and forming techniques structures the two layers forming the bra body to take on specific characteristics and functions despite the entire bra body essentially being simply a tubular construction of the material being used. In light of the two layer construction of the bra body, the two layers may be referred to herein as an inner layer (i.e., the layer that would be adjacent the body of a user when being worn) and an outer layer (i.e., the layer that would be outwardly visible when being worn by a user). The use of such terms should not be viewed as limiting the scope of the invention but is only provided for ease of understanding and complete description of the invention.

In light of the above, in specific embodiments, the bra cups can be described as being formed of an inner layer and an outer layer, the two layers being shaped and structured form a “pocket”. Although the bra body is essentially a tube of bra material, the method of manufacture structures the bra so that the transitions between the defined parts of the bra effectively compartmentalize the bra. For example, as seen in FIG. 1, the bra 100 further comprises backwings 121 and 128 that extend laterally away from the expansible cups. The term “backwings” is descriptive of the structure and function of this component of the bra since they extend away from the cups (i.e., as wings) and encircle the body of the user to meet in the back. Of course, the term “backwings” should not be viewed as limiting the scope of this element of the inventive bra, and it would be expected to encompass other known terminology, such as an “under-bust band”.

The backwings (being part of the tubular construction of the seamless bra body) can be described as having a double-folded construction. Moreover, the backwings are particularly woven or otherwise formed so that the two layers lie essentially flat against one another. For example, techniques such as the use of variegated ribs or specific weaving or knitting styles, such as jacquard, jersey, waffle, and the like, can be used to impart preferred characteristics to the backwings, including improved elastic support, structural integrity, and overall comfort. This specialized structure effectively separates the backwings from the expansible cups. In other words, although there is no stitching or seaming to physically separate the cups from the backwings (i.e., the space between the two layers remains open and transitions directly and openly from the cups to the backwings), the structural differences between the cups and the backwings imparted by the weaving and knitting techniques used effectively isolates the distinct parts of the bra and allows the bra to maintain its structure.

In particular embodiments, the backwings are substantially triangle-shaped. As seen in FIG. 1, the height of the backwing from the hem to the top edge trimming adjacent the cup is greater than the height of the backwing at the terminal end. Since the backwing is substantially straight along the hem, this height difference essentially forms a triangular shape. This is beneficial to provide increased back support in the bra. In bras with backwings that are substantially a straight cut shape, weight is not well distributed by the bra, and the breast weight tends to be borne by the cups and the shoulder straps. The triangular shape of the backwings according to the present invention effectively distributes the breast weight away from the front and allows some of the weight to be supported across the back, which eases the front burden and the “digging in” of the shoulder straps.

Although the backwings extend laterally away from the cups, in some embodiments, the backwings can also exist (in part) under the cups. As see in FIG. 1, a portion of each backwing extends under the cups and meets in the midline of the bra. This arises from the essentially tubular construction of the preliminary bra body. In other embodiments, the cups may be formed so that no portion of the backwings exists under the bra cups or so that the backwings do not meet at the bra midline.

In specific embodiments, the expansible cups are formed of a different construction from the backwings so that the expansible form the pocket mentioned above. Such different construction can include a different weaving or knitting technique or other different forming method so that the two layers forming the cups are less inclined to position themselves in an essentially flat conformation (i.e., one layer laying flay against the other layer).

As illustrated by the dashed line in FIG. 1, the varying construction of the defined sections of the bra body (i.e., differentiating the backwings from the cups) forms a pocket in each bra cup. This pocket can be particularly designed for receiving other elements of the bra. It is thus useful for the pocket to be accessible. Accordingly, the bra cups can be defined as having an “open access pocket” for receiving other bra elements.

As more fully described below, the preliminary bra body can be essentially open along the top edge of the bra body. The bra body can by “closed” and thus made into a finished bra by trimming the top edge (e.g., providing an elastic binding). In specific embodiments, the elastic binding can be attached to the top edge of the bra body such that the pockets in the expansible cups are not complete closed. Various methods can be used to provide the cup pockets with an open access structure. As illustrated in FIG. 2, which shows the bra from an inner view (i.e., the side of the bra that would be against the body of a user), access to the pocket can be provided by forming the inner layer 112 of the cup 111 to have an inset portion with an edge that does not align with the corresponding edge of the outer layer 113. This inset portion does not get bound by the elastic binding and thus leaves an open access to the pocket in the cup. Such a conformation is particularly useful to form the bra so that the pocket (and the access to the pocket) remains concealed from external view. Thus, the pocket according to this embodiment is accessible on an inward-facing surface of the expansible cup. Of course, other methods could be used to form the open access to the cup pocket. For example, the binding along a length of the cup could simply be omitted. Moreover, further components could be used, including closure means for the pocket access (e.g., a loop and hook means, a snap or button means, or the like).

The open access pocket in the expansible cups is particularly useful to allow for insertion of additional bra components. For example, in specific embodiments, the bra can comprise a formed support and shape element. This can generally comprises an element that is formed of a material that provides support and shape to bra cup. The element can be formed of any material providing these functions, such as a foam, silicone, gel, or other material. Preferably, the element is formed to substantially correspond to the shape and/or dimensions of the cup pocket. In particular, the element is formed to provide a padding and/or concealing and/or smoothing effect for the underlying breast.

In particular embodiments, the formed support and shape element is formed to substantially correspond to a particular bra cup size, such as a normally recognized cup size (e.g., size “A”, size “B”, size “C”, or size “D”). In other embodiments, the formed support and shape element can be formed to substantially correspond to a specific breast volume or volume range (e.g., a volume of about 13 fl. oz. (384 cm³) to substantially correspond to a “B” cup, a volume of about 21 fl. oz. (621 cm³) to substantially correspond to a “C” cup, or a volume range of between about 13 fl. oz. (384 cm³) and about 21 fl. oz. (621 cm³) to substantially cover the full range of what may be considered a “B” cup). One embodiment of a formed support and shape element useful according to the invention is provided in FIG. 3. The support and shape element 200 in this embodiment is substantially disc shaped. The element can vary in thickness and other dimensions and shape. Preferably, the element is “formed” to have a natural curvature that substantially corresponds to a breast shape and can thus provide a natural fit with good comfort and support.

The formed support and shape element is preferably formed to be flexible and provide good comfort to a user. In particular, the element should be capable of easy insertion and removal from the open access pocket formed in the extensible cups. This enables a user to alter the bra cup size to a desired size. This functionality is particularly described by the exemplary embodiment below, which is provided to ensure clarity as to the interchangeable formed support and shape elements for customizing bra fit and function.

For example, a woman entering maternity may have a bra size of “34B”. Such a woman could wear a bra according to the invention that is sized to match a standard 34B size (i.e., having the proper circumference and have expansible cups providing proper support for a “B” cup). The bra according to the invention can include a formed support and shape element that is designed to substantially match a “B” cup. During pregnancy, the woman's breast may become enlarged such that the “B” cup element is no longer comfortable and/or no longer provides proper support. The woman could remove the “B” cup element through the open access in the cup pocket and instead insert a formed support and shape element that substantially corresponds to a “C” cup. The expansible nature of the cups would allow for the larger support and shape element while likewise continuing to provide proper support and shape to the user. This unique interchangeability of the support and shape element in the extensible bra cups makes the inventive bra capable of use throughout a period of rapidly changing breast size. Likewise, after pregnancy, if the woman's breast decrease in size such that the “C” cup support and shape element was too big, that element could be removed and replaced with the original (or a new) “B” cup support and shape element. The stretch recovery of the extensible cups allows the cups to regain the smaller size and again provide proper support and shape the woman's smaller breasts.

In the course of practical use, as described above, it is clear that the inventive bra effectively reduces time expenditures and costs associated with maternity-related body changes or body changes arising over a relatively short time period in relation to other events or causes. The inventive bra is formed of a material that is durable and can be washed multiple times without damage or reduction in comfort and support. Because of the expansible cups, interchangeable support and shape elements, and specifically designed material weaving and knitting techniques, the bra of the invention can beneficially be used over the entire course of a pregnancy (both before and after baby delivery). Thus, a bra of a single “size” according to the invention can be used over the course of a full year (or even more) encompassing a maternity period characterized by changes in breast size (e.g., breast volume and/or overall circumference in the bust region). This is a significant departure from the art, wherein changes in breast size require the purchase of a new bra of a different size. According to the known art, a woman having significant changes in breast size during a maternity period could be required to purchase bras in two, three, four, or even more different size combinations to provide the desired and appropriate level of comfort and support (e.g., different variations in cup size and overall circumference). According to the present invention, a bra of a single “size” could be used over the entire maternity period, the features described herein providing perfect fit across the full spectrum of body and breast changes during the maternity period. Thus, the user saves the time and cost of purchasing multiple different bras with every change in breast size.

Of course, it is not required that both cups of the bra be simultaneously sized. As previously noted herein, many women experience breast volume asymmetry. The present invention is particularly useful to address this problem as each bra cup can be sized independently of the other. For example, if a woman had one breast with a volume equating to a “B” cup and other breast with a volume equating to a “C” cup, the inventive bra would be particularly useful since the woman could customize the two cups so that each breast was cupped with the exact size to match the asymmetry. Moreover, if desired, the woman could insert further element (e.g., padding) into the pocket of the cup for the smaller breast to make that breast appear fuller, thus correcting the asymmetry. Accordingly, the woman's breasts would take on an outwardly symmetrical appearance. The invention thus encompasses a method of non-surgically correcting breast asymmetry by providing a bra according to the invention and filling one pocket of the bra with a material sufficient to compensate for a breast volume underlying the bra cup pocket that is smaller than the breast volume underlying the other bra cup pocket.

Returning to the embodiment of FIG. 1, the backwings 121 and 128 of the bra 100 have terminal ends that define the attachment points for connecting the ends of the backwings around the body of a user. Any means recognized as useful in the art for attaching the terminal ends of a bra to “clasp” the bra around the user could be used according to the invention. In the illustrated embodiment, the terminal end of backwing 121 comprises a series of hooks 141, and the terminal end of the other backwing 128 comprises a series of eyelets 148 for receiving the hooks. Of course, other closure methods could be used according to the invention. Moreover, the closure means can be attached to the bra body by any useful means, including stitching.

In some embodiments, the bra size can be further adjustable by effectively lengthening the backwings. For example, FIG. 1 includes a call-out FIG. 1B, which illustrates an eye and hook extension piece 300 that can be provided with a bra according to the invention.

In addition to changes in breast volume, bra size can also change in relation to body circumference. In many instances, both body circumference and breast volume can change. Such changes can be simultaneous or sequential. In any event, in addition to allowing for changes in breast volume (as described above) the bra of the invention can also accommodate circumference changes, particularly through provision of the noted extension. This provides for maximum control of bra sizing to achieve complete comfort and support.

The bra illustrated in the embodiment of FIG. 1 further comprises a lower edge that is hemmed. The word “hem” is not necessarily used herein in the typical sense of the word. Specifically, a “hem” does not refer to any stitching used along the lower edge of the bra. Rather, hem refers to a section of the bra body that is doubled back on itself (i.e., “double-folded”) and defines the lower edge of the bra body. Similar to the backwings, the hem 160 is particularly formed (such as through weaving or knitting methods) so that the double-folded layers of material lie essentially flat against one another. This is made possible even without the need for stitching or seaming, and the bra still maintains an open, “tubular” arrangement between the two layers. Preferably, the hem has a ribbed structure, which can be particularly beneficial to provide support under the bust-line and at the back. This added support can be particularly beneficial to assist in “raising” the bust and relieving stresses from other supporting structures of the bra.

The hem of the inventive bra is also useful to provide room for expansion, such as during the growth stages of maternity. The folded rib hem particularly provides for a very comfortable feel of expansion in comparison to the known art. For example, it is common to provide an elasticized hem along the bottom edge of a bra to provide a snug, yet expandable fit. Such elastic hems, however, are sorely lacking in comfort. The hem of the present bra overcomes this limitation in the art by provide good fit and support along the lower edge of the bra that is also very comfortable to the user and provides good freedom of movement.

The inventive bra can further comprise a center gore between the expansible cups that is structured to further facilitate expansibility of the cups. As illustrated in FIG. 1, the gore 150 is positioned between the two expansible cups 111 and 118 and provides a stabilizing effect. In specific embodiments, the center gore is structured to have a reduced degree of stretch in relation to the remaining portions of the bra body. In one embodiment, the center gore has a “waffle” design. This reduced stretch provides a central positioning anchor that assists in maintaining the bra perfectly positioned on the user's body, despite the stretch ability of the bra. Moreover, this anchor point forms a base from which the remaining portions of the bra can stretch. In particular, the central gore of reduced stretch ability anchors the midpoint of the bra body between the user's breasts so that the extensible bra cups can perfectly align with the user's breasts and provide the required amount of stretch to conform to the user's breast while provide the desired level of comfort and the required amount of support.

In specific embodiments, the center gore having the reduced stretch ability forms a vertical gathering of the cups near the center gore (as illustrated by the fold lines 151 and 158 in FIG. 1). This vertical gathering enhances perfect fits by keeping the cups anchored to the midpoint of the bra body so that the cups “fan out” around the breasts to encompass and support rather than merely conforming to the existing breast shape and position. This reduced stretch center gore likewise functions to “pull” the breasts up and toward the midpoint of the bra, which mechanically reduces stress on the bra straps and can enhance breast position on the body and even enhance cleavage.

The center gore design according to the invention is also useful to maximize a “scoop-neck” design that is aesthetically pleasing. Many maternity bras sacrifice form for function; however, the bra of the present invention using structural means, such as the reduced stretch center gore, to improve the shape of the bra, such as providing a scoop-neck design allowing the bra to be worn with a variety of fashions. Moreover, the scoop-neck design is beneficial to facilitate functional aspects of certain embodiments of the bra, such as the drop-down cup described herein.

As noted above, the inventive bra can further include shoulder straps. In one embodiment (as seen in FIG. 1), the shoulder straps 171 and 178 can be attached at one end to the extensible cups and at the opposing end to the backwing. The shoulder straps are preferably sizable to increase or decrease in length to maximize comfort and support. Of course, any type of shoulder strap known in the art (including using specific types of comfort padding and stretch materials) could be used according to the invention. Moreover, the shoulder straps could be attached to the bra body at different locations along the top edge of the bra body.

As previously pointed out, the bra of the invention is particularly useful as a maternity bra since pregnancy can result in significant changes in breast size over the course of just a few months. Likewise, after childbirth, women can have functionality needs in relation to bra, including further changes in breast size and the need for easy access for breast feeding a baby. In particular embodiments, the bra of the present invention can particularly meet the needs of mother who are breast feeding their babies.

For example, FIG. 4 illustrates a bra according to the invention comprising an extensible cup wherein the pocket formed in the cup comprises a drop-down panel. Thus, the pocket can be described as a “drop-down pocket”. The detail view of FIG. 4 particularly shows the connection of the bra strap 178 to the extensible cup 118 via a connecting piece 188. The connecting piece 188 is particularly designed to independently connect the outer layer 120 and inner layer 119 of the cup 118 to the bra strap 178. This is further shown in FIG. 5, which shows the outer layer 120 of the cup 118 released from its attachment to the connecting piece 188 and position in a drop-down state. The inner layer 119 of the cup 118 remains attached to the connecting piece 188. In specific embodiments, the connecting piece 188 may particularly be a buckle. In some embodiments, the connection between the inner layer and the connection piece is a permanent attachment (i.e., cannot be detached apart from destructive means).

The connecting piece can take on any structure useful to allow independent connection of the inner and outer cup layers to the bra strap. In the illustrated embodiment, the inner layer is attached to the bra strap with a double loop connection; however, the bottom loop includes a projection 190 over which a loop 191 independently attached to the outer cup layer can be hooked. In such embodiments, the inner cup layer can be described as being permanently attached to the bra strap (or to the connecting piece), and the outer cup layer can be described as being releasably attached to the bra strap (or to the connecting piece).

Of course, other means of independent attachment could be used. For example, the inner layer could be attached to the bra strap, and the outer lay could be attached to the inner layer, such as with a hook and loop means, a snap means, or the like.

Release of the outer layer of the cup is preferably useful to provide access to the underlying breast for breast feeding. Accordingly, it is useful for the inner and outer layers of the cup to be aligned in a sufficiently offset manner to expose the breast via the drop-down of the outer layer. For example, the inner could only partially cover the breast such that the inner layer could be easily moved aside to provide access for breast feeding. This can be achieved by separately applying trimming (e.g., elastic binding) to the inner and outer cup layers.

In particular embodiments, the inner cup layer can be formed as bias cut panels (i.e., having a slanting stretch direction). By biasing the stretch direction of the inner cup layer, the inner layer is easier to move to the side to provide access for breast feeding. This is a distinct formation from a typical stretch panel that provides equal degrees of stretch in all stretch directions. The bias cut panel, however, is designed to maximize stretch in a specific direction to make it easier to move the panel to one direction.

In light of the various bra embodiments described above, the present invention also includes a number of further aspects. For example, various bra components as described above may be combined and packaged as a bra kit. In one embodiment, a bra kit according to the invention provides a bra that is adaptable to a variety of breast sizes and includes all elements for adapting the single bra to the various sizes. Particularly, the bra kit may include a bra comprising expansible cups, each cup having an open access pocket. The bra kit may also include support and shape elements designed for insertion into the open access pocket. The support and shape elements can be provided in a variety of shapes, sizes, number, and combinations. In specific embodiments, a plurality of pairs of support and shape elements may be provided, and each pair of support and shape elements may be formed to substantially correspond to different particular bra cup sizes.

In one embodiment, a bra kit may comprise the bra and two or more sets of support and shape elements that are selected from the following groups: substantially “A” size elements; substantially “B” size elements; substantially “C” size elements; substantially “D” size elements; and substantially “DD” size elements. Of course, the support and shape elements could be sized differently (including relating more closely to exact breast volume, as described above) and could include smaller, bigger, and/or intermediate sizes. Importantly, the kits preferably contain at least two different sizes (preferably consecutive sizes) of support and shape element. This kit provides the user with the elements needed to easily convert the bra to a different size as the breast volume changes.

In certain embodiments, the bra included in the kit may comprise cups that are designed to be expansible over a broader or narrower range, as described above, and the kits would be expected to include support and shape elements that would substantially correspond to the bra cup sizes for which the bran is intended. For example, kits could include a bra and support and shape elements useful for breast volumes in the range of “A” to “B”, “A” to “C”, “A” to “D”, “B” to “C”, “B” to “D”, “B” to “DD”, “C” to “D”, “C” to “DD”, or “D” to “DD”. Of course, the kit could accommodate other size ranges as well.

The kit may further include other elements useful in making the bra fully sizable to provide the maximum support and comfort during times of changing breast size. For example, the bra kit could further include a separable eye and hook extension piece, as described above, that effectively expands the overall circumference of the bra. Likewise, the bra could comprise adjustable buckles or hood and loop type fasteners on the shoulder straps to provide for further adjustability of the straps.

Although the above bra kit is described in terms of use by individuals going through times of changing breast size, such as during maternity, the use of the kit is not so limited. Rather, kits could be customized for use by women having breast asymmetries. In such embodiments, the kits could further include items (such as paddings) that are useful to insert into the open access pocket to “pad” the cup covering the smaller breast and thus improve and/or correct the breast asymmetry.

In another aspect, the invention also encompasses methods of preparing a bra with expansible cups. In one embodiment, the method comprises forming preliminary bra body having a tubular construction. Preferably, the bra body is formed using an elastic material as described herein. In specific embodiments, the material is elastic (or has a defined stretch recovery) in multiple directions, particularly in at least two directions.

Forming the bra body can comprise multiple preliminary procedures. For example, forming can begin with a designer (e.g., tailor) who customizes the intended bra to be in accord with the breast shape (and volumes) of the desired users (e.g., maternity women). A computer drawing can be sketched using the customized design. In order to provide a customized fit, different knitting textures can be included in the designs. For example, the bra can be designed to include one or more of variegated ribs, and jacquard, jersey, and waffle weaves or knits. The computer design can be linked to a weaving machine (e.g., a Santoni machine) by appropriate software, and the preliminary bra body can be formed as a knitted panel in a substantially tubular form. This preliminary bra body can undergo further processing, such as dying and further tailoring and trimming.

As discussed above, the computer-controlled knitting process uses the designs and knitting techniques to provide the preliminary bra body with a fairly complete design. For example, the knitting process can further comprise shaping the preliminary bra structure to have a top edge and a bottom edge ad to define the two expansible cups that have an inner layer and an outer layer. This can be achieved by knitting the preliminary bra body such that the backwing sections have a designed texture and/or knit (e.g., a reinforced variegated rib texture). Likewise, the hem can be formed to be a double-folded rib and can have specific texturing as well. In contrast, the bra cups can forego such specialized knitting so that these sections of the bra do not have the “tight” fit of the backwings and the hem.

The production methods can also comprise trimming of the top edge of the preliminary bra body to form the finished bra body. For example, the inner and outer layers of the expansible cup may be joined by the trimming on the top edges of the cups (i.e., along the top periphery of the cups). This trimming finishes the bra and closes the “tubular” structure. The trimming step particularly comprises leaving an opening in each cup to form the open access pocket. For example, application of the trimming could be skipped along a length of the top periphery of the cups. Alternately, the inner cup layer could be formed to have an inset section such that upon application the trimming, the inset section does not receive the trimming and an opening remains to provide access to the pocket. Of course, other means could also be used to form the access opening into the cup pockets. In specific embodiments, the trimming may comprise elastic binding, which may be attached by any useful means, such as stitching.

The inventive may also incorporate various techniques to secure the pull strength of the various attachment points (i.e., joint seams) of the bra components. For example, the shoulder strap is attached to the bra body at two points. Likewise, the eye and hook pieces must be attached to the terminal ends of the backwings. Such attachments can be specially formed to make 'strong” attachments that can effectively function to form areas of leverage to allow the bra to comfortably stretch during movement. For example, this can be accomplished by using bar tacking at these joint seams.

In still further embodiments, cushioning can be applied to the straps. Such cushioning can be substantially the same width of the existing bra straps or may have different dimensions. Moreover, the cushioning may be positioned at discrete positions along the bra strap or may be present substantially along a specific length of the bra strap or along the entire length of the bra strap. Such cushioning can be useful to maximize front support provided for the breasts, as well as increasing wearer comfort.

EXAMPLES Bra Dimensions

A bra according to one embodiment of the invention is schematically illustrated in FIG. 6. The dimensions for the labeled components are provided below in Table 1.

TABLE 1 Label Description Length (in.) A Under bust length (include 1^(st) eye hook) 24.75 B Cup height 8.00 C Front scoop neckline 10.50 D Underarm length 9.50 E Center gore height 3.75 F Strap length (2 in. adjustment) 10.25

Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing description. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. 

1. A bra comprising expansible cups, each cup having an open access pocket for receiving a formed support and shape element that substantially corresponds to a particular bra cup size.
 2. The bra of claim 1, wherein the pocket is concealed from external view.
 3. The bra of claim 2, wherein the pocket is accessible on an inward-facing surface of the expansible cup.
 4. The bra of claim 1, comprising backwings extending laterally away from the expansible cups and having a double-folded, textured knit construction.
 5. The bra of claim 4, wherein the backwings have a substantially triangular shape.
 6. The bra of claim 4, comprising a series of eyelets at an end of one backwing and a series of hooks at an end of the other backwing, and further comprising a separable eye and hook extension piece that effectively expands the overall circumference of the bra.
 7. The bra of claim 1, comprising a hemmed lower edge having a double-folded, textured knit construction.
 8. The bra of claim 1, comprising a center gore between the expansible cups, the center gore having a reduced stretch ability in relation to the expansible cups and being constructed to form a vertical gathering of the cups near the center gore.
 9. The bra of claim 1, wherein the pocket is a drop-down pocket.
 10. The bra of claim 9, wherein at least one cup is formed of an outer material layer and an inner material layer, each layer comprising a top portion that is independently attached to a connecting piece.
 11. The bra of claim 10, wherein the connecting piece connects the outer material layer and the inner material to an over-shoulder strap.
 12. The bra of claim 10, wherein the inner material layer is permanently attached to connecting piece and the outer material layer is releasably attached to the connecting piece.
 13. The bra of claim 12, wherein the inner material layer and the outer material layer are aligned in a sufficiently offset manner such that release of the connection of the outer material layer allows the outer material layer to drop down and expose the underlying breast of a user.
 14. The bra of claim 10, wherein the cup inner material layer is a bias cut panel having a slanting stretch direction.
 15. The bra of claim 1, wherein the bra comprises a bra body that is formed of a seamless construction.
 16. The bra of claim 15, wherein the bra body comprises the expansible cups, backwings, a center gore, and a bottom hem.
 17. The bra of claim 1, comprising a support and shape element that is formed to substantially correspond to a particular bra cup size.
 18. A bra kit providing a bra that is adaptable to a variety of breast sizes, the bra kit comprising: A) a bra comprising expansible cups, each cup having an open access pocket; and B) a plurality of pairs of support and shape elements designed for insertion into the open access pocket, each pair of support and shape elements being formed to substantially correspond to different particular bra cup sizes.
 19. The bra kit of claim 18, wherein the bra further comprises backwings extending laterally away from the expansible cups and having a double-folded, textured woven construction.
 20. The bra kit of claim 19, further comprising: C) a separable eye and hook extension piece that effectively expands the overall circumference of the bra.
 21. A method of making a bra with expansible cups, the method comprising: A) forming a preliminary bra body having a tubular construction and comprising a material that is elastic in multiple directions; B) shaping the preliminary bra body to have a top edge and a bottom edge and to define two expansible cups having an inner layer and an outer layer; and C) trimming the top edge of the preliminary bra body to form a finished bra body, wherein the inner and outer expansible cup layers are joined by the trimming on the top edges of the cups leaving an opening that forms an open access pocket in the expansible cup. 